Changeover Checklist Template

The changeover checklist is divided into three phases following SMED methodology. The **Pre-Changeover (External)** section lists all preparation activities that can and should be completed while the current product is still running: gathering tools and fixtures, preheating molds or dies, staging materials, reviewing work instructions, and preparing quality inspection gauges. The **During Changeover (Internal)** section lists the activities that require the machine to be stopped: removing old tooling, installing new tooling, adjusting settings, and threading new material. Each activity includes the responsible person, estimated time, and a completion checkbox. The **Post-Changeover Verification** section covers startup activities: running test pieces, checking quality against specifications, adjusting parameters, and confirming production readiness. A summary footer tracks total changeover time (internal only), compares it to the target time, and notes improvement opportunities for the next changeover.

Customize the checklist for each specific machine and product changeover combination — a generic checklist is less effective than one tailored to the actual activities required. Involve the operators and setup technicians who perform the changeover in creating the checklist; they know the process details best. Before each changeover, the setup technician reviews the external activities list and ensures everything is prepared before the machine stops. During the changeover, the team works through the internal activities in sequence, checking off each item and noting the actual time versus the estimated time. After the first good part is confirmed, complete the verification section. Record the total changeover time and any deviations from the standard procedure. Review changeover data weekly to identify patterns: Are certain changeovers consistently taking longer than target? Are specific activities bottlenecking the process? Use these insights to drive SMED kaizen events that systematically reduce changeover times, enabling smaller batch sizes in the LinePlanner production schedule.

The changeover checklist is both an operational tool and an improvement tool. Operationally, it ensures consistency — every changeover follows the same optimized procedure, regardless of which operator or shift performs it. For improvement, the time data collected with each changeover provides the baseline for SMED projects. Analyze the data to find the longest internal activities and ask: Can this be converted to external (done before the machine stops)? Can this be eliminated entirely? Can two activities be done in parallel by two people? Can a quick-release mechanism replace bolts? Can a fixed stop replace a manual adjustment? Each improvement should be reflected in an updated checklist that becomes the new standard. Track changeover time trends on a visual management board near the equipment — this public visibility motivates continued improvement. As changeover times decrease, communicate the scheduling benefit to the planning team: shorter changeovers mean smaller minimum batch sizes, which means more flexibility in the production calendar.